Hydrogen Tank Protective Layer Insulation

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Solution Overview

Problem

Fuel cell vehicles' hydrogen tanks face challenges in managing heat generated by external devices, which can increase hydrogen pressure and require wide control ranges for pressure reducing valves, potentially leading to fuel cell deterioration and inefficient hydrogen consumption.

Innovation Solution

A pressure vessel configuration with a liner, a fiber-reinforced plastic reinforcing layer, and a protective layer featuring thermally foamed material between fiber materials, which insulates against heat and prevents direct damage, reducing heat transmission and maintaining hydrogen pressure stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a conventional single-layer protective coating is applied to the hydrogen tank, then manufacturing simplicity is maintained, but heat insulation performance is insufficient leading to hydrogen pressure increase

Engineering Contradiction:

Improveheat insulation performanceVSAvoidprotective layer structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The protective layer is constructed as a composite material system combining organic resin coating with inorganic heat-resistant particles (such as alumina, silica, or zirconia). This composite structure provides both heat insulation functionality and chemical resistance, resolving the contradiction between thermal protection and structural complexity by integrating multiple functions into a single layered system.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The protective layer is designed with spatially varying properties: the outer surface contains high concentrations of heat-resistant particles for thermal protection, while the inner surface maintains better adhesion to the tank body. This local differentiation allows the same protective layer to fulfill multiple regional requirements simultaneously.

Inventive Principle:

Principle #3Local quality

2Ease of operation

If no heat insulation措施 is taken, then manufacturing cost is low, but hydrogen pressure control range becomes wide requiring frequent valve adjustments

Engineering Contradiction:

Improvepressure control precisionVSAvoidheat insulation structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent converts the harmful effect of external heat into a beneficial protective mechanism by using heat-resistant particles that reflect and scatter thermal radiation. The particles absorb and dissipate heat energy, transforming the thermal challenge into an opportunity for enhanced thermal management without complex active cooling systems.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If the protective layer uses only organic resin, then application simplicity is maintained, but heat resistance and chemical resistance are insufficient

Engineering Contradiction:

Improvechemical resistanceVSAvoidprotective layer application

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively reduces heat input into the hydrogen tank, preventing pressure increases, narrowing the control range of pressure reducing valves, enhancing fuel cell durability, and improving hydrogen efficiency while also reducing manufacturing costs and increasing productivity.

Implementation Method 1

A protective layer is provided on an outer surface of the reinforcing layer and includes fiber materials and a thermally foamed material. The thermally foamed material is interposed between the fiber materials.

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS8507060B2Pressure vessel

Publication Date: 2013.08.13 HONDA MOTOR CO LTD

AI summary

A pressure vessel includes a liner, a reinforcing layer, and a protective layer. An inside of the liner forms a reserving chamber. The reinforcing layer is made of fiber reinforced plastic and is provided on an outer surface of the liner. A protective layer is provided on an outer surface of the reinforcing layer and includes fiber materials and a thermally foamed material. The thermally foamed material is interposed between the fiber materials.